Manufacturing device



May 27, 1958 d Sept. 25, 1956 INVENTOR. .Do/v E. Ks-Y "Unito Etates MANUFACTURHQG DEVICE Application September 25, 1956, Serial No. 611,341

Claims. (Cl. 51-281) This invention relates to a method and apparatus for manufacturing Storage battery separators and is more particularly concerned With a method and apparatus for forming individual hard rubber separators fron a strip of cured ru'nber material.

ln the manufacture of hard rubber separators as used in present day storage batteries, the materials for the separator are first compounded and then formed into strips of considerable length which are Wound into a roll before curing. These rolls usually have a Width several times the width of the separators which are to be cut therefrom. The Wide strip is usually provided With longitudinully extending Weakened portions which are spaced traversely across the strip to facilitate the division of the Wide strip into individual strips each having a Width substantially equal to the Width of the individual separators.

The separators used in present day batteries are usualljl provided with a smooth surface on one side and a corrugated or embossed surface on the other side. This corrugated or embossed surface is formed during manufacture in the Wide strip prior to the curing step. lt is to he appreciated that a large number of separators are used in each battery that is manufactured. Thus, it is n.cessary if high battery production is to be achieved, hat the individual separators be rapidly and economically formed to exact dimensions. The apparatus and method of the present invention are directed to realizing this objective for the apparatus according to the present invention is able to accommodate one hundred or more linear feet per minute of moving strip material Without difficulty.

lt is an object therefore of the present nvention to divide a moving strip of relatively brittle hard rubber material into individual pieces of predetermined dimension.

Another object of the present invention is to provide an apparatus which Will divide a continuously moving strip of brittle hard ru'ober battery separator material into longitudinal strips, to size the divided strips by grinding the edges and surfaces thereof and to push the strip by means of revolvng rolls between a cutting roll that is driven at a predetermined speed and a roll that is freely rotatable so that individual separators of each having a predetermined length Will be severed from the moving strips.

A still further object is to form hard rubber battery separators from a continuously moving strip of relatively brittle material wherein the strip has a Width equal to a multiple of the Width of the separators to be formed therefrom by an apparatus which Will slit the Wide strips into individual strips each having a Width substantially equal to a separator Width, size the strip both as to thielrness and Width to predetermined separator dimensions, push the moving strips between an idler backing roll and a roll With cutting means thereon which is driven at a predetermined speed relative to the rolls which cause the pushing action to sever the strips into atent individual pieces of predetermined length and to convey the cut pieces away from the rolls which cut the strip material.

1n carrying out the above objects it is another object of the present invention to provide a means for varying the speed of rotation between the pusher rolls and the driven roll wlnch has the cutting means thereon for varying the length of the pieces which are cut from the moving strip.

lt is still another object of the present invention to process a continuously moving strip of relatively brittle hard rubber separator material which has a smooth surface on one side and an embossed or corrugated surface on the other side and to sever the strip into individual strips which have substantially the same Width as the separator to be formed and to size the strip both as to thickness and Width before the individual strips are severed into separator lengths by a pair of rolls which have the strip fed thereto by a pair of rolls which are driven at a predetermined speed relative to only one of the rolls which perform the severing operation.

Further objects and advantages of the present invention will be apparent from the following description, reference being had to the accompanying drawings Wherein a preferred embodiment of the present invention is clearly shown.

In the drawings; the single figure diagrammati-cally in perspective shows an apparatus for sizeing and dividing a continuously moving strip of relatively brittle hard rubber separator material.

In the drawing the wide uncut strip 2% of cured hard rubber separator material is continuously presented to the apparatus dagrammatically shown from a source, not shown. The strip 2%, is relatively brittle in nature and is formed to have a relatively smooth surface on one side and an embossed or corrugated surface on the opposite side. In the embodment shown, the upper surface of the strip 3% is provided with longitudinally extending corrugations. The strip 20 is formed to have a Width which is some multiple of the separators which are to be formed as for example thestrip Ztl has a Width three times the Width of the separators 22, and includes wealtened portions 24. These weakened portions 24 extend longitudinally over the entire length of the strip and divide the strip Ztl into 3 segments each of which is slightly larger than the Width of a separator 22.

The strip 29 is initially fed in the direction of arrow 26 to the slitters 23 which are transversely spaced to engage the weakened portions 24 and divide the strip 2% into three segments 30 each having a Width slightly greater than the Width of the separators 22. The slitters 23 may either be rollers, as shown, or knives which will cause the strip 26 to be divided into equal strips 30.

After the strip 2% is divided, the individual segments 30 are fed between the grindng wheels 32 and 31%. These wheels 32 and 34 are rotated by a suitable means, not shown, and are used to grind the strips 36 to a predetermined thiclmess. In the embodinent shown, the strips 39 are disposed so the corrugated surface is on top and engages Wheel 32. The smooth surface of the strip 31) is located to be engaged by the Wheel 34. Manifestly, if desired, only one surface of the strip need be ground during the sizing operation. For example, roll 34 may have a non-abrading surface in contact with the smooth surface of strip f) while the abrading sur-face on Wheel 32 Contacts and rernoves the top portions of the ridges which form the corrugated surface of strip 39.

After the strips 30 are sized to the correct thckness they are passed between the revolving abrading discs 36 which are also driven by a suitable means, not shown. The discs 36 are transversely spaced and arranged to rolls V38 and .40 Will-be equal.

grind the edges on both sides of the strips 30 so each of the strips Will have the Width of the separators 22.

After the strips 30 are sized Vby the discs 36 they are guided by suitable means as rollers 37, and passed between'rollers 38 and 40. These rollers are rotated in synchronism by the motor 42 and are driven by means 44 which may consist of a pulley and belt'arrangement or a chain 'and sprocket combination so the rotation of The roll 40 is provided witha'smooth metallic outer surface that engages the smooth surface of strip 30. 'The roll 38 is provided With an outer surface of a suitable elastorneric material which engages the corrugated surface of the strip^30.

The elastomeric surface may be of any ofV the well- Vknown rubbery material suchas natural or synthetic rubbers, combinations thereof, or any similar materials which will engage and conform to the corrugated surface of strip 30 without deforming the strip 30; The rolls 38 and 40are vertically disposedV one .above one another and are pressed together to tightly engagefboth sides of the strip. While'any suitable means may be used to cause the pressure between'the rolls* 38 and .40, in' the i embodiment shown an' air cylinder 46 is used to irripart an upward force thfough yoke '48 on'the roll .40. i

The rolls 38 and 40` are used to'drive or feed the strip .30 between rolls 48. and 50. The roll 50 is provided with a smooth oute .metallic surfacefwhieh engages the smooth under surface of strip 30. vThe roll 50 is Vfreely rotatable and is rotated by the moving strip 30. 'The roll-43 on the other hand isV rotated in synchronism at a predetermined speed ratio relative to rolls 33 and 40 by means of gears 52 and 54 and either of the gears 56 and 57 or gear 58 as will be later'described. A

The roll 48 is provided with circumferentially spaced cutters 60 thereon. These cutters may be made detachable if desired and` are arranged so a slight clearance is present between the edges of the cutters 60 and the outer surface of roll 50. Thns, as the strip material passes between the rolls 48-and 50, the cutters 60 Will be moved into position'- and sever the stript into pieces or separators 22 each of Vwhich Will have a predetermined length. As stated, the cutt'ers 69 are in a Clearance relation with the surface of roll 50. Thus, as the cutters 60 are rotated into. the strip -30 they will initially bite into the strip and then' cause the remaining portion of the brittle strip material to snap or-break of the strip length. As can be clearlyV seen on the drawing the cutter blades 60 are staggered in their location. on the roll or drum 48. Thus, thefvarious parallel strips 30 will be severed at different intervals. When this Varrangement is used the Stress on the various parts of the apparatus is considerably reduced.

After the separators 22 are cut to the desired lengths by'cutters 60`they are pushed on the guide 62V and fall on the belt conveyor 64 which moves in the direction of arrow 66. The conveyor 64 may be used to convey the separators to a dryingoven if desired, and thence to a stacking device also 'not shown.

As clearly seen in the drawing' a suitable means is pro-.

vided to' drive roll 48 at a synchronized speed relative to the rotational speeds of rolls 38 and 40. .This means is capable of varying the relative speeds 'between the rollers so separators of different lengths may be severed from the strip 30. Thus, when handle'g is in the position shown, gear 52 will drive gearV 57V which in turnWill drive gear 56. Gear 57 has a smaller diameter than gear 52 so gear 56 will rotate fas'ter` than gear 52. When this gear arrangement is used a short length separator will be separated from the strip 30. Where the handle 68 is moved downwardlyV the gearsV 57 and 56 will be moved from their driving engagernent with gears 52 and 541 respectively and gear' Will be brought into engagement therewith so thatthe gears 52 and 54 turn at the same' Vrotational speed. Thismeans rollerV 48-will rotate at the same speed as roller 38 or slower' than when the roller is driven by gears 56* and 57. When this arrangement is used the separators of longer length will'beV 1. In a method for making battery'plate separators from relatively brittle strip material of indeterminate length and of a breadth equal to at least two times the Width ofV a single separator wherein said strip material' is embossed on one side and is smooth on the other side, the steps comprising; pulling the strip material V from a source of supply to move the stripat a constant rate of travel while simultaneously resilently supportingV Vthe embossed side ther'eof, slitting the moving strip longitudinally into a plurality of'individual strips each having a Width equal to the Width of a single separator, sizing the strip both as to Width and thickness, pushing said slit strips into a rotating severing device for cutting said strip into a plurality of individual separators and conveying the individual-separators from said separating device.

2. Ina method forV making battery plate separators from relatively brittle strip material of indeterminate length and ofia breadth equal to at least two times the VWidth of Va single separator wherein said strip material is embossed on one side and is smooth on the other side, the steps 'comprising; pulling the strip materialwfrom a source of' Supply toV move the strip at a constant rate of travel while simultaneously resiliently supportin'g the embossed side thereof, slitting the moving strip longi-I tudinally into a plurality of individual strips each having' a Width equal to the Width of a single separator,

grinding the edges, and the smooth and embossed surfaces of each strip to size the strips to a predetermined Width andV thickness, pushing said slit strips into a `rotating severing device for cutting said strip into a plurality of individual separators and conveying theV indi-V vidual separators from said separating device.

3. In a method for making battery plate separators from normally brittle strip material of indeterminate length and of a breadth equal to at least two times the Width of a single separator wherein said strip has an embossed andV a substantially smooth side, the steps comprising; pullingthe strip material from a source of snpplyv at a constant rate of travel whilesirnultaneously resiliently supporting the embossed side thereof, slitting the moving strip longitudinally into a plurality of parallel individual stripsleach having a Width equal to the Width of a single separator,V

grinding the edges of said strip to size the strip to a predetermined Width, pushing said strip into a rotating severing device having staggered cutting means .thereon for severing said individual parallel strips transversely at staggered intervals from'the embossed side thereof into... Va plurality of individual separators, and finally conveying said separators from the severing means.

4. An apparatus forsevering Storage battery separatorsV from a plurality of continuously moving 'parallel'strips of relatively brittle material wherein one side of said'strpsis substantially smooth and the other side isV provided with a corrugated surface, comprisin'g; a pair of verticallyi disposed rolls arrangedffor receiving said strip material 'therebetweem one of said rolls having a substantiallyV smooth metallic outer surface for engaging the smooth side of said strips and'the other having an elastomeric outer surface for engagng the corrugated surface thereof, a second pair of vertically disposed rolls arranged to receive said strip therebetween after'said strip material has passed between said first pair of rolls, one of said secondV pair of rolls having cutting means disposed at predetermincd staggered intervals about the periphey thereof ar-` ranged to be rnoved successively into engagement With the emhossed surface of said strip, the other of said second pair of rolls being freeigV rotatahle and having a substantiaily smooth metailic outer surface for engaging the snooth surface of said strip fer rertically supporting said strip While the cutfing means of said first roll severs the strip into individual pieces of material, and means for sirnultaneously driving both rolls of said first pair of rolls at the same speed of rotation and the roll carrying the cutting means at a predeterrnired speed of rotation relative to the rotation of said rst pair of rolis for causing said pieces to have predetermined length.

5. An apparatus for severing Storage battery separators from a plurality of continuously moving parallel strips of relatively brittle material whercin one side of said strip is substantially smooth and the other side is provided with an embossed surface, comprising; a pair of vertically disposed rolls arranged for receiving said strip material therebetween, one of said rolls having a substantally srnooth metallic outer surface for engaging the smooth side of said strips and the other having an elastomerc outer surface for engaging the embossed surface thereof and which deforms under pressure to the contour of the embossed surfaces, a second pair of vertically disposed rolls arranged to receive said strip therebetween after said strip material has passed between said first pair of rolls, one of said second pair of rolls having cutting means disposed at predetermined intervals about the periphery thereof arranged to be rao-ver successively into engagement with the ernhossed su 'ace of said strip, the other of said second pair of rolls being fleely rotatable and having a suhstantiaily srnoo'zh rnetailic outer surface for en` gaging the srnooth surface of said strip for vertically supporting said strip while the c .ing means of said first roll severs the strip into indivi uai pieces of material, and means fer simultaneousiy driving both rolls of said firs pair of rolls at the same speed of rotation and for driving the roll g the cutting at a predetermined speed of roton relative to the rotation of said first pair of rolls for causing sain pieces to have a predetermined length and means for causing a different relative rotational speed between said first pair of rolls and the roll carrying the cutting means for Changing the length of said severed pieces.

References Cited in the file of this patent UNITED STATES PATENTS Re. 22,123 Egerton June 23, 1942 797,886 Deely Aug. 22, 1905 1,006,783 Paquin Oct. 24, 1911 1,107,762 Curnfer Aug. 18, 1914 1,176,680 Langston Mar. 21, 1916 1,370,381 Tarbox Mar. 1, 1921 

